95G2V Gas Furnace Downflow Installation Manual

INSTALLATION INSTRUCTIONS
A95DF2V, 95G2DFV
Warm Air Gas Furnace / Downflow Air Discharge
Direct Vent & Non-Direct Vent
This manual must be left with the homeowner for future reference.
This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in
manuals, be alert to the potential for personal injury or death.
WARNING
CAUTION
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must
be performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
TABLE OF CONTENTS
Vent Piping Guidelines..................................................... 16
Gas Piping........................................................................ 35
Electrical........................................................................... 37
Control Diagnostics.......................................................... 42
Unit Start-Up..................................................................... 46
Gas Pressure Adjustment................................................. 47
High Altitude Information.................................................. 48
Other Unit Adjustments.................................................... 49
Blower Motor Performance............................................... 50
Service ........................................................................... 52
Planned Service............................................................... 54
Repair Parts List............................................................... 55
Start-Up & Performance Check List................................. 56
Unit Dimensions................................................................. 2
Parts Arrangement............................................................. 3
Gas Furnace....................................................................... 4
Shipping and Packing List.................................................. 4
Safety Information.............................................................. 4
Use of Furnace as Construction Heater............................. 5
General ............................................................................. 6
Combustion, Dilution & Ventilation Air................................ 6
Setting Equipment.............................................................. 9
Filters ........................................................................... 12
Duct System..................................................................... 12
Pipe & Fittings Specifications........................................... 12
Joint Cementing Procedure.............................................. 14
Venting Practices.............................................................. 14
Manufactured By
Allied Air Enterprises LLC
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
*P507052-04*
(P) 507052-04
507052-04
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Unit Dimensions - inches (mm)
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Expanded View
Figure 1
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Gas Furnace
This Category IV gas furnace is shipped ready for installation
in the downflow position.
The furnace is equipped for installation in natural gas
applications. A conversion kit (ordered separately) is
required for use in LP/propane gas applications.
This unit can be installed as either a Direct Vent or a
Non-Direct Vent gas central furnace.
NOTE: In Direct Vent installations, combustion air is taken
from outdoors and flue gases are discharged outdoors.
Non-Direct Vent installations, combustion air is taken from
indoors or ventilated attic or crawl space and flue gases are
discharged outdoors. See Figures 2A and 2B for application
involving roof termination.
Shipping and Packing List
Package 1 of 1 contains:
1- Assembled Gas Unit
1- Bag assembly containing the following:
1 - Snap bushing
1 - Snap Plug
1 - Wire tie
1 - Condensate trap
1 - Condensate trap cap
1 - Condensate trap clamp
1 - 2” diameter debris screen
1 - 3/4” Threaded street elbow
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
Please refer to specification sheets for available accessories.
Safety Information
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must
be performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
CAUTION
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
Figure 2A
DANGER
DANGER OF EXPLOSION!
There are circumstances in which odorant used with
LP/propane gas can lose its scent. In case of a leak,
LP/propane gas will settle close to the floor and may be
difficult to smell. An LP/propane leak detector should
be installed in all LP applications.
Use only the type of gas approved for use with this furnace.
Refer to unit nameplate.
This unit is CSA International certified to ANSI Z21.47 and
CSA 2.3 standards.
Figure 2B
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Building Codes
In the USA, installation of gas furnaces must conform with
local building codes. In the absence of local codes, units
must be installed according to the current National Fuel
Gas Code (ANSI Z223.1/NFPA 54). The National Fuel Gas
Code is available from the American National Standards
Institute, Inc., 11 West 42nd Street, New York, NY 10036.
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In Canada, installation must conform with current National
Standard of Canada CSA-B149 Natural Gas and Propane
Installation Codes, local plumbing or waste water codes and
other applicable local codes.
In order to ensure proper unit operation in non-direct vent
applications, combustion and ventilation air supply must be
provided according to the current National Fuel Gas Code
or CSA-B149 standard.
Locations and Clearances
This furnace is CSA International certified for installation
clearances to combustible material as listed on the unit
nameplate and in the table in Figure 13. Accessibility
and service clearances must take precedence over fire
protection clearances.
NOTE: When furnace is installed on a combustible floor,
a downflow combustible flooring base must be installed
between the furnace and the floor.
For installation in a residential garage, the furnace must be
installed so that the burner(s) and the ignition source are
located no less than 18 inches (457 mm) above the floor.
The furnace must be located or protected to avoid physical
damage by vehicles. When a furnace is installed in a public
garage, hangar, or other building that has a hazardous
atmosphere, the furnace must be installed according to
recommended good practice requirements and current
National Fuel Gas Code or CSA B149 standards.
Note: Furnace must be adjusted to obtain a temperature
rise within the range specified on the unit nameplate. Failure
to do so may cause erratic limit operation and premature
heat exchanger failure.
This gas furnace must be installed so that its electrical
components are protected from water.
Installed in Combination with a Cooling Coil
When this furnace is used with cooling units (Figure 3),
it shall be installed in parallel with, or on the upstream
side of, cooling units to avoid condensation in the heating
compartment. With a parallel flow arrangement, a damper
(or other means to control the flow of air) must adequately
prevent chilled air from entering the furnace. If the damper is
manually operated, it must be equipped to prevent operation
of either the heating or the cooling unit, unless it is in the
full HEAT or COOL setting.
When installed, this furnace must be electrically grounded
according to local codes. In addition, in the United States,
installation must conform with the current National Electric
Code, ANSI/NFPA No. 70. The National Electric Code
(ANSI/NFPA No. 70) is available from the following address:
National Fire Protection Association
1 Battery March Park
Quincy, MA 02269
507052-04
Figure 3
In Canada, all electrical wiring and grounding for the unit
must be installed according to the current regulations of
the Canadian Electrical Code Part I (CSA Standard C22.1)
and/or local codes.
NOTE: This furnace is designed for a minimum continuous
return air temperature of 60°F (16°C) or an intermittent
operation down to 55°F (13°C) dry bulb for cases where a
night setback thermostat is used. Return air temperature
must not exceed 85°F (29°C) dry bulb.
This gas furnace may be installed in alcoves, closets, attics,
basements, garages, and utility rooms.
This furnace design has NOT been CSA certified for
installation in mobile homes, recreational vehicles, or
outdoors.
Never use an open flame to test for gas leaks. Check all
connections using a commercially available soap solution
made specifically for leak detection.
Use of Furnace as Construction Heater
These units are not recommended for use as a construction
heater during any phase of construction. Very low return air
temperature, harmful vapors and operation of the unit with
clogged or misplaced filters will damage the unit.
These units may be used for heating of buildings or
structures under construction, if the following conditions
are met:
• The vent system must be permanently installed per
these installation instructions.
• A room thermostat must control the furnace. The use
of fixed jumpers that will provide continuous heating is
not allowed.
• The return air duct must be provided and sealed to the
furnace.
• Return air temperature range between 60°F (16°C) and
80°F (27°C) must be maintained.
• Air filters must be installed in the system and must be
maintained during construction.
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•
•
•
•
•
Air filters must be replaced upon construction completion.
The input rate and temperature rise must be set per the
furnace rating plate.
One hundred percent (100%) outdoor air must be provided
for combustion air requirements during construction.
Temporary ducting may supply outdoor air to the furnace.
Do not connect duct directly to the furnace. Size the
temporary duct following the instructions in section for
Combustion, Dilution and Ventilation Air in a confined
space with air from outside.
The furnace heat exchanger, components, duct system,
air filters and evaporator coils must be thoroughly
cleaned following final construction cleanup.
All furnace operating conditions (including ignition, input
rate, temperature rise and venting) must be verified
according to these installation instructions.
General
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
WARNING
The State of California has determined that this product
may contain or produce a chemical or chemicals, in
very low doses, which may cause serious illness or
death. It may also cause cancer, birth defects or other
reproductive harm.
Combustion, Dilution & Ventilation Air
If this unit is installed as a Non-Direct Vent Furnace,
follow the guidelines in this section.
NOTE: In Non-Direct Vent Installations, combustion air is
taken from indoors and flue gases are discharged outdoors.
In addition to the requirements outlined previously, the
following general recommendations must be considered
when installing one of these furnaces:
WARNING
Insufficient combustion air can cause headaches,
nausea, dizziness or asphyxiation. It will also cause
excess water in the heat exchanger resulting in rusting
and premature heat exchanger failure. Excessive
exposure to contaminated combustion air will result
in safety and performance related problems. Avoid
exposure to the following substances in the combustion
air supply:
Permanent wave solutions
• Place the furnace as close to the center of the air
distribution system as possible. The furnace should
also be located close to the vent termination point.
• When the furnace is installed in non-direct vent
applications, do not install the furnace where drafts
might blow directly into it. This could cause improper
combustion and unsafe operation.
• When the furnace is installed in a non-direct vent
applications, do not block the furnace combustion air
opening with clothing, boxes, doors, etc. Air is needed
for proper combustion and safe unit operation.
• When the furnace is installed in an attic or other
insulated space, keep insulation away from the furnace.
• When the furnace is installed in an unconditioned space,
consider provisions required to prevent freezing of the
condensate drain system.
NOTE: The Commonwealth of Massachusetts stipulates
these additional requirements:
• Gas furnaces shall be installed by a licensed plumber
or fitter only.
• The gas cock must be “T handle” type.
• When a furnace is installed in an attic, the passageway
to and service area surrounding the equipment shall be
floored.
CAUTION
These units should not be installed in areas normally
subject to freezing temperatures.
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Chlorinated waxes and cleaners
Chlorine base swimming pool chemicals
Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
In the past, there was no problem in bringing in sufficient
outdoor air for combustion. Infiltration provided all the air
that was needed. In today’s homes, tight construction
practices make it necessary to bring in air from outside for
combustion. Take into account that exhaust fans, appliance
vents, chimneys, and fireplaces force additional air that
could be used for combustion out of the house. Unless
outside
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air is brought into the house for combustion, negative
pressure (outside pressure is greater than inside pressure)
will build to the point that a down draft can occur in the
furnace vent pipe or chimney. As a result, combustion
gases enter the living space creating a potentially dangerous
situation.
In the absence of local codes concerning air for combustion
and ventilation, use the guidelines and procedures in this
section to install these furnaces to ensure efficient and safe
operation. You must consider combustion air needs and
requirements for exhaust vents and gas piping. A portion
of this information has been reprinted with permission from
the National Fuel Gas Code (ANSI-Z223.1/NFPA 54). This
reprinted material is not the complete and official position
of ANSI on the referenced subject, which is represented
only by the standard in its entirely.
infiltration. If the furnace is located in a building of tight
construction with weather stripping and caulking around
the windows and doors, follow the procedures in the “Air
from Outside” section.
Confined Space
A confined space is an area with a volume less than 50
cubic feet (1.42 m³) per 1,000 Btu (.29 kW) per hour of
the combined input rating of all appliances installed in that
space. This definition includes furnace closets or small
equipment rooms.
Do not install the furnace in a corrosive or contaminated
atmosphere. Meet all combustion and ventilation air
requirements, as well as all local codes.
When the furnace is installed so that supply ducts carry
air circulated by the furnace to areas outside the space
containing the furnace, the return air must be handled by
ducts which are sealed to the furnace casing and which
terminate outside the space containing the furnace. This
is especially important when the furnace is mounted on
a platform in a confined space such as a closet or small
equipment room. Even a small leak around the base of the
unit at the platform or at the return air duct connection can
cause a potentially dangerous negative pressure condition.
Air for combustion and ventilation can be brought into the
confined space either from inside the building or from
outside.
All gas-fired appliances require air for the combustion
process. If sufficient combustion air is not available, the
furnace or other appliance will operate inefficiently and
unsafely. Enough air must be provided to meet the needs of
all fuel-burning appliances and appliances such as exhaust
fans which force air out of the house. When fireplaces,
exhaust fans, or clothes dryers are used at the same time
as the furnace, much more air is required to ensure proper
combustion and to prevent a down draft. Insufficient air
causes incomplete combustion which can result in carbon
monoxide.
Air from Inside
If the confined space that houses the furnace adjoins a
space categorized as unconfined, air can be brought in by
providing two permanent openings between the two spaces.
Each opening must have a minimum free area of 1 square
inch (645 mm²) per 1,000 Btu (.29 kW) per hour of total
input rating of all gas-fired equipment in the confined space.
Each opening must be at least 100 square inches (64516
mm²). One opening shall be within 12 inches (305 mm) of
the top of the enclosure and one opening within 12 inches
(305 mm) of the bottom. See Figure 4.
In addition to providing combustion air, fresh outdoor air
dilutes contaminants in the indoor air. These contaminants
may include bleaches, adhesives, detergents, solvents and
other contaminants which can corrode furnace components.
Equipment in Confined Space - All Air from Inside
In Canada, refer to the CSA B149 Installation codes.
CAUTION
The requirements for providing air for combustion and
ventilation depend largely on whether the furnace is installed
in an unconfined or a confined space.
Unconfined Space
An unconfined space is an area such as a basement or large
equipment room with a volume greater than 50 cubic feet
(1.42 m³) per 1,000 Btu (.29 kW) per hour of the combined
input rating of all appliances installed in that space. This
space also includes adjacent rooms which are not separated
by a door. Though an area may appear to be unconfined,
it might be necessary to bring in outdoor air for combustion
if the structure does not provide enough air by
Figure 4
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Air from Outside
If air from outside is brought in for combustion and
ventilation, the confined space shall be provided with two
permanent openings. One opening shall be within 12” (305
mm) of the top of the enclosure and one within 12” (305
mm) of the bottom. These openings must communicate
directly or by ducts with the outdoors or spaces (crawl or
attic) that freely communicate with the outdoors or indirectly
through vertical ducts. Each opening shall have a minimum
free area of 1 square inch per 4,000 Btu (645 mm² per .59
kW) per hour of the total input rating of all equipment in the
enclosure (See Figures 5 and 6).
Equipment in Confined Space - All Air from Outside
(All Air Through Ventilated Attic)
It is also permissible to bring air for combustion from a
ventilated attic (Figure 8) or ventilated crawl space (Figure
9).
Figure 6
Equipment in Confined Space - All Air from Outside
(Inlet Air from Crawl Space and Outlet Air to Ventilated Attic)
Equipment in Confined Space - all Air from Outside
Figure 5
When communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of 1
square inch (645 mm²) per 2,000 Btu (.56 kW) per hour of
the total input rating of all equipment in the enclosure. See
Figure 7.
When ducts are used, they shall be of the same crosssectional area as the free area of the openings to which they
connect. The minimum dimension of rectangular air ducts
shall be no less than 3 inches (75 mm). In calculating free
area, the blocking effect of louvers, grilles, or screens must
be considered. If the design and free area of protective
covering is not known for calculating the size opening
required, it may be assumed that wood louvers will have 20
to 25 percent free area and metal louvers and grilles will
have 60 to 75 percent free area. Louvers and grilles must be
fixed in the open position or interlocked with the equipment
so that they are opened automatically during equipment
operation.
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Figure 7
Equipment in Confined Space
(Inlet Air from Ventilated Attic & Outlet Air to Outside)
Figure 8
507052-04
Allow for clearances to combustible materials as indicated
on the unit nameplate. Minimum clearances for closet or
alcove installations are shown in Figure 13.
Equipment in Confined Space
(Inlet Air from Ventilated Crawlspace & Outlet Air to Outside)
Units with 1/2 HP Blower Motor
Figure 10
WARNING
Blower access panel must be securely in place when
blower and burners are operating. Gas fumes, which
could contain carbon monoxide, can be drawn into living
space resulting in personal injury or death.
Figure 9
Setting Equipment
INSTALLATION – Setting Equipment
WARNING
Do not install the furnace on its front, back or in the
horizontal position. See Figure 12. Do no connect the
return air ducts to the back of the furnace. Doing so
will adversely affect the operation of the safety control
devices, which could result in personal injury or death.
Select a location that allows for the required clearances that
are listed on the unit nameplate. Also consider gas supply
connections, electrical supply, vent connection, condensate
trap and drain connections, and installation and service
clearances [24 inches (610 mm) at unit front]. The unit must
be level from side to side. Tilt the unit slightly (maximum
1/2 in. from level) from back to front to aid in the draining of
the heat exchanger. See Figure 11.
Figure 11
Shipping Bolt Removal
NOTE: Units with a 1/2 hp blower motors are equipped with
three flexible legs and one rigid leg. The rigid leg is equipped
with a shipping bolt and a flat white plastic washer (rather
than the rubber mounting grommet used with a flexible
mounting leg). See Figure 10. The bolt and washer must
be removed before the furnace is placed into operation.
After the bolt and washer have been removed, the rigid leg
will not touch the blower housing.
507052-04
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Figure 12
Page 9 of 58
Installation on Non-Combustible Flooring
1. Cut floor opening keeping in mind clearances listed
on unit rating plate. Also keep in mind gas supply
connections, electrical supply, flue and air intake
connections and sufficient installation and servicing
clearances. See Table 1 for correct floor opening size.
2. Flange warm air plenum and lower the plenum into the
opening.
3. Set the unit over the plenum and seal the plenum to the
unit.
4. Ensure that the seal is adequate.
WARNING
Improper installation of the furnace can result in
personal injury or death. Combustion and flue products
must never be allowed to enter the return air system
or air in the living space. Use sheet metal screws and
joint tape to seal return air system to furnace.
In platform installations with furnace return, the furnace
should be sealed airtight to the return air plenum. A
door must never be used as a portion of the return air
duct system. The base must provide a stable support
and an airtight seal to the furnace. Allow absolutely no
sagging, cracks, gaps, etc.
Non-Combustible Floor Opening Size
For no reason should return and supply air duct systems
ever be connected to or from other heating devices such
as a fireplace or stove, etc. Fire, explosion, carbon
monoxide poisoning, personal injury and/or property
damage could result.
Table 1
The unit may be installed three ways in downflow
applications: on non-combustible flooring, on combustible
flooring using an additive base, or on a reverse-flow cooling
coil cabinet. Do not drag the unit across the floor in the
downflow position. Floor and furnace flange damage
will result.
Refer to Figure
13 for clearances in downflow applications.
Downflow Application Installation Clearances
Figure 14
Installation on Combustible Flooring
1. When unit is installed on a combustible floor, a downflow
combustible flooring base must be installed between
the furnace and the floor. The base must be ordered
separately. See Table 2 for opening size to cut in floor.
CAUTION
The furnace and combustible flooring base shall not be
installed directly on carpeting, tile, or other combustible
material other than wood flooring.
Figure 13
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Combustible Flooring Base Opening Size
Table 2
Figure 16
Figure 15
2. After opening is cut, set the combustible flooring base
into opening.
3. Check fiberglass strips on the combustible flooring base
to make sure they are properly glued and positioned.
4. Lower supply air plenum into the combustible flooring
base until plenum flanges seal against fiberglass strips.
er opening is
NOTE: Be careful not to damage fiberglass strips. Check
for a tight seal.
Return Air Opening - Downflow Units
Return air may be brought in only through the top opening of
a furnace installed in the downflow position. The following
steps should be taken when installing plenum:
1. Bottom edge of plenum should be flanged with a
hemmed edge (See Figure 17 or 18).
2. Sealing strips should be used to ensure an airtight seal
between the cabinet and the plenum.
3. In all cases, plenum should be secured to top of furnace
using sheet metal screws.
4. Make certain that an adequate seal is made.
5. Set the furnace over the plenum.
6. Ensure that the seal between the furnace and plenum
is adequate.
Figure 17
Installation on Cooling Coil Cabinet
NOTE: Downflow combustible flooring kit is not used.
1. Refer to reverse-flow coil installation instructions for
correctly sized opening in floor and installation of
cabinet.
2. When cooling cabinet is in place, set and secure the
furnace according to the instructions that are provided
with the cooling coil. Secure the furnace to the cabinet.
3. Seal the cabinet and check for air leaks.
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Figure 18
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Filters
This unit is not equipped with a filter or rack. A field provided
filter is required for the unit to operate properly. Table 3 lists
recommended filter sizes.
A filter must be in place whenever the unit is operating.
Pipe & Fittings Specifications
All pipe, fittings, primer and solvent cement must conform
with American National Standard Institute and the American
Society for Testing and Materials (ANSI/ASTM) standards.
The solvent shall be free flowing and contain no lumps,
undissolved particles or any foreign matter that adversely
affects the joint strength or chemical resistance of the
cement. The cement shall show no gelation, stratification,
or separation that cannot be removed by stirring. Refer
to Table 4 below for approved piping and fitting materials.
Table 3
CAUTION
Solvent cements for plastic pipe are flammable liquids
and should be kept away from all sources of ignition.
Do not use excessive amounts of solvent cement when
making joints. Good ventilation should be maintained to
reduce fire hazard and to minimize breathing of solvent
vapors. Avoid contact of cement with skin and eyes.
Duct System
Use industry-approved standards to size and install the
supply and return air duct system. This will result in a quiet
and low-static system that has uniform air distribution.
NOTE: This furnace is not certified for operation in heating
mode (indoor blower operating at selected heating speed)
with an external static pressure which exceeds 0.8 inches
w.c. Operation at these conditions may result in improper
limit operation.
Supply Air Plenum
If the fumace is installed without a cooling coil, a removable
access panel should be installed in the supply air duct. The
access panel should be large enough to permit inspection
(by reflected light) of the heat exchanger for leaks after the
furnace is installed. The furnace access panel must always
be in place when the furnace is operating and it must not
allow leaks into the supply air duct system.
Return Air Plenum
NOTE: Return air must not be drawn from a room where
this furnace, or any other gas-fueled appliance (i.e., water
heater), or carbon monoxide-producing device (i.e., wood
fireplace) is installed.
When return air is drawn from a room, a negative pressure
is created in the room. If a gas appliance is operating in a
room with negative pressure, the flue products can be pulled
back down the vent pipe and into the room. This reverse
flow of the flue gas may result in incomplete combustion
and the formation of carbon monoxide gas. This toxic
gas might then be distributed throughout the house by the
furnace duct system.
Use fiberglass sealing strips, caulking, or equivalent sealing
method between the plenum and the furnace cabinet to
ensure a tight seal. If a filter is installed, size the return air
duct to fit the filter frame.
PIPING AND FITTINGS SPECIFICATIONS
Schedule 40 PVC (Pipe)
Schedule 40 PVC (Cellular Core Pipe)
Schedule 40 PVC (Fittings)
Schedule 40 CPVC (Pipe)
Schedule 40 CPVC (Fittings)
SDR-21 PVC or SDR-26 PVC (Pipe)
SDR-21 CPVC or SDR-26 CPVC (Pipe)
Schedule 40 ABS Cellular Core DWV
(Pipe)
Schedule 40 ABS (Pipe)
Schedule 40 ABS (Fittings)
ABS-DWV (Drain Waste & Vent)
(Pipe & Fittings)
PVC-DWV (Drain Waste & Vent)
Pipe & Fittings)
PRIMER & SOLVENT CEMENT
PVC & CPVC Primer
PVC Solvent Cement
CPVC Solvent Cement
ABS Solvent Cement
PVC/CPVC/ABS All Purpose Cement For
Fittings & Pipe of the same material
ABS to PVC or CPVC Transition Solvent
Cement
CANADA PIPE & FITTING & SOLVENT
CEMENT
PVC & CPVC Pipe and Fittings
PVC & CPVC Solvent Cement
ABS to PVC or CPVC Transition Cement
POLYPROPYLENE VENTING SYSTEM
PolyPro® by Duravent
InnoFlue® by Centrotherm
D1785
F891
D2466
F441
F438
D2241
F442
F628
D1527
D2468
D2661
D2665
ASTM
SPECIFICATION
F656
D2564
F493
D2235
D2564, D2235,
F493
D3138
MARKING
ULCS636
ULC-S636
ULC-S636
Table 2
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vent pipe hangers. Uniformly apply a liberal coat of PVC
primer for PVC or use a clean dry cloth for ABS to clean
inside socket surface of fitting and male end of pipe to depth
of fitting socket.
IMPORTANT
The exhaust and intake connections are made of PVC.
Use PVC primer and solvent cement when using PVC
vent pipe. When using ABS vent pipe, use transitional
solvent cement to make connections to the PVC fitting
in the unit.
Use PVC primer and solvent cement or ABS solvent cement
meeting ASTM specifications, refer to Table 4. As an
alternate, use all purpose cement, to bond ABS, PVC, or
CPVC pipe when using fittings and pipe made of the same
materials. Use transition solvent cement when bonding ABS
to either PVC or CPVC.
Low temperature solvent cement is recommended during
cooler weather. Metal or plastic strapping may be used as
Canadian Applications Only
Pipe, fittings, primer and solvent cement used to vent
(exhaust) this appliance must be certified to ULC S636 and
supplied by a single manufacturer as part of an approved
vent (exhaust) system. When bonding the vent system to
the furnace, use ULC S636 approved One-Step Transition
Cement to bond the pipe to the flue collar. In addition, the
first three feet of vent pipe from the furnace flue collar must
be accessible for inspection.
Table 5 lists the available exhaust termination kits. All vent
terminations are PVC.
Outdoor Termination Kits Usage
Table 5
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Joint Cementing Procedure
All cementing of joints should be done according to the
specifications outlined in ASTM D 2855.
Venting Practices
Piping Suspension Guidelines
NOTE: A sheet metal screw may be used to secure the
intake pipe to the connector, if desired. Use a drill or self
tapping screw to make a pilot hole.
DANGER
DANGER OF EXPLOSION!
Fumes from PVC glue may ignite during system check.
Allow fumes to dissipate for at least 5 minutes before
placing unit into operation.
1. Measure and cut vent pipe to desired length.
2. Debur and chamfer end of pipe, removing any ridges
or rough edges. If end is not chamfered, edge of pipe
may remove cement from fitting socket and result in a
leaking joint.
3. Clean and dry surfaces to be joined.
4. Test fit joint and mark depth of fitting on outside of pipe.
5. Uniformly apply a liberal coat of PVC primer for PVC
or use a clean dry cloth for ABS to clean inside socket
surface of fitting and male end of pipe to depth of fitting
socket.
6. Promptly apply solvent cement to end of pipe and inside
socket surface of fitting. Cement should be applied
lightly but uniformly to inside of socket. Take care to
keep excess cement out of socket. Apply second coat
to end of pipe.
NOTE: Time is critical at this stage. Do Not allow Primer
to dry before applying cement.
7. Immediately after applying last coat of cement to pipe,
and while both inside socket surface and end of pipe
are wet with cement, forcefully insert end of pipe into
socket until it bottoms out. Turn PVC pipe 1/4 turn
during assembly (but not after pipe is fully inserted) to
distribute cement evenly. Do not turn ABS or cellular
core pipe.
Figure 19
Removal of the Furnace from Common Vent
In the event that an existing furnace is removed from a
venting system commonly run with separate gas appliances,
the venting system is likely to be too large to properly vent
the remaining attached appliances.
Conduct the following test while each appliance is operating
and the other appliances (which are not operating) remain
connected to the common venting system. If the venting
system has been installed improperly, you must correct the
system as indicated in the general venting requirements
section.
NOTE: Assembly should be completed within 20 seconds
after last application of cement. Hammer blows should not
be used when inserting pipe.
8. After assembly, wipe excess cement from pipe at end
of fitting socket. A properly made joint will show a bead
around its entire perimeter. Any gaps may indicate an
improper defective assembly due to insufficient solvent.
9. Handle joints carefully until completely set.
Page 14 of 58
Issue 1621
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placed into operation could result in carbon monoxide
poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation.
507052-04
1. Seal any unused openings in the common venting
system.
2. Inspect the venting system for proper size and horizontal
pitch. Determine that there is no blockage, restriction,
leakage, corrosion, or other deficiencies which could
cause an unsafe condition.
3. Close all building doors and windows and all doors
between the space in which the appliances remaining
connected to the common venting system are located
and other spaces of the building. Turn ON clothes
dryers and any appliances not connected to the common
venting system. Turn ON any exhaust fans, such as
range hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
4. Follow the lighting instructions. Turn ON the appliance
that is being inspected. Adjust the thermostat so that
the appliance operates continuously.
5. After the main burner has operated for 5 minutes, test
for leaks of flue gases at the draft hood relief opening.
Use the flame of a match or candle.
6. After determining that each appliance connected to
the common venting system is venting properly, (step
3) return all doors, windows, exhaust fans, fireplace
dampers, and any other gas burning appliances to their
previous mode of operation.
7. If a venting problem is found during any of the preceding
tests, the common venting system must be modified to
correct the problems.
Resize the common venting system to the minimum vent
pipe size determined by using the appropriate tables in
Appendix G. These are in the current standards of the
National Fuel Gas Code ANSI Z223.1.
Figure 20
1. In areas where piping penetrates joist or interior walls,
hole must be large enough to allow clearance on all
sides of pipe through center of hole using a hanger.
2. When furnace is installed in a residence where unit
is shut down for an extended period of time, such
as a vacation home, make provisions for draining
condensate collection trap and lines.
Exhaust Piping
Route piping to outside of structure. Continue with
installation following instructions given in piping termination
section.
CAUTION
Do not discharge exhaust into an existing stack or
stack that also serves another gas appliance. If vertical
discharge through an existing unused stack is required,
insert PVC pipe inside the stack until the end is even
with the top or outlet end of the metal stack.
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Page 15 of 58
Use the following steps to correctly size vent pipe diameter.
CAUTION
The exhaust vent pipe operates under positive pressure
and must be completely sealed to prevent leakage of
combustion products into the living space.
Vent Piping Guidelines
This gas furnace can be installed as either a Non-Direct
Vent or a Direct Vent gas central furnace.
NOTE: In non-Direct Vent installations, combustion air is
taken from indoors and flue gases are discharged outdoors.
In Direct Vent installations, combustion air is taken from
outdoors and flue gases are discharged outdoors.
Intake and exhaust pipe sizing - Size pipe according
to Tables 6 and 7. Table 6 lists the minimum vent pipe
lengths permitted. Table 7A - 7C lists the maximum pipe
lengths permitted.
Regardless of the diameter of pipe used, the standard roof
and wall terminations described in section Exhaust Piping
Terminations should be used. Exhaust vent termination
pipe is sized to optimize the velocity of the exhaust gas as
it exits the termination.
Table 6
Figure 21
In some applications which permit the use of several different
sizes of vent pipe, a combination vent pipe may be used.
Contact Allied Air Technical Service for assistance in sizing
vent pipe in these applications.
IMPORTANT
Do not use screens or perforated metal in exhaust or
intake terminations. Doing so will cause freeze-ups and
may block the terminations.
Page 16 of 58
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507052-04
A95DF2V & 95G2DFV
Table 7A
507052-04
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Page 17 of 58
A95DF2V & 95G2DFV
Table 7B
Page 18 of 58
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507052-04
A95DF2V & 95G2DFV
Table 7C
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Page 19 of 58
Typical Exhaust Pipe Connections
Figure 22
Typical Intake Pipe Connections (Direct Vent Applications)
Figure 23
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507052-04
Intake Piping
This furnace may be installed in either direct vent or nondirect vent applications. In non-direct vent applications,
when intake air will be drawn into the furnace from the
surrounding space, the indoor air quality must be considered.
Guidelines listed in Combustion, Dilution and Ventilation Air
section must be followed.
Follow the next two steps when installing the unit in Direct
Vent applications, where combustion air is taken from
outdoors and flue gases are discharged outdoors. The
provided air intake screen must not be used in direct
vent applications (outdoors).
1. Use cement or a sheet metal screw to secure the intake
pipe to the inlet air connector.
2. Route piping to outside of structure. Continue with
installation following instructions given in general guide
lines for piping terminations and intake and exhaust
piping terminations for direct vent sections. Refer to
Table 7A-7C for pipe sizes.
Follow the next two steps when installing the unit in Non­
Direct Vent applications where combustion air is taken
from indoors and flue gases are discharged outdoors.
1. Use field-provided materials and the factory-provided
air intake screen to route the intake piping. Maintain a
minimum clearance of 3” (76 mm) around the air intake
opening. The air intake opening (with the protective
screen) should always be directed forward, or sideways.
2. If intake air is drawn from a ventilated crawlspace
(Figure 25) or ventilated attic (Figure 24) the exhaust
vent length must not exceed those listed in Table 7C.
If 3” diameter pipe is used, reduce to 2” diameter pipe
to accommodate the debris screen.
3. Use a sheet metal screw to secure the intake pipe to
the connector, if desired.
Equipment in Confined Space
(Inlet Air from Ventilated Attic and Outlet Air to Outside)
Figure 25
General Guidelines for Vent Terminations
In Non-Direct Vent applications, combustion air is taken from
indoors and the flue gases are discharged to the outdoors.
This unit is then classified as a non-direct vent, Category
IV gas furnace.
In Direct Vent applications, combustion air is taken from
outdoors and the flue gases are discharged to the outdoors.
This unit is then classified as a direct vent, Category IV gas
furnace.
In both Non-Direct Vent and Direct Vent applications, the
vent termination is limited by local building codes. In the
absence of local codes, refer to the current National Fuel
Gas Code ANSI Z223-1/NFPA 54 in U.S.A., and current
CSA-B149 Natural Gas and Propane Installation Codes in
Canada for details.
Figure 24
507052-04
Position termination according to location given in Figure 26
or 27. In addition, position termination so it is free from any
obstructions and 12” above the average snow accumulation.
At vent termination, care must be taken to maintain
protective coatings over building materials (prolonged
exposure to exhaust condensate can destroy protective
coatings). It is recommended that the exhaust outlet not be
located within 6 feet (1.8 m) of a condensing unit because
the condensate can damage the painted coating.
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Page 21 of 58
NOTE: See Table 8 for maximum allowed exhaust pipe
length without insulation in unconditioned space during
winter design temperatures below 32° F (0° C). If required,
exhaust pipe should be insulated with 1/2” (13 mm), Armaflex
or equivalent when run through an unconditioned area. In
extremely cold climate areas with temperature below 20° F
(6.7° C) it is recommended that 3/4” (19 mm) Armaflex or
equivalent be used. Insulation on outside runs of exhaust
pipe should be painted or wrapped to protect insulation
from deterioration in accordance with the insulation
manufacturers recommendation. Exhaust pipe insulation
may not be necessary in some specific applications.
IMPORTANT
Do not use screens or perforated metal in exhaust
terminations. Doing so will cause freeze-ups and may
block the terminations.
IMPORTANT
For Canadian Installations Only:
In accordance to CSA International B149 installation
codes, the minimum allowed distance between the
combustion air intake inlet and the exhaust outlet of
other appliances shall not be less than 12 inches (305
mm).
NOTE: During extremely cold temperatures, below
approximately 20° F (6° C), units with long runs of vent
pipe through unconditioned space, even when insulated,
may form ice in the exhaust termination that prevents the
unit from operating properly. Longer run times of at least 5
minutes will alleviate most icing problems. Also, a heating
cable may be installed on exhaust piping and termination
to prevent freeze-ups. Heating cable installation kits are
available, see unit specification sheets for part numbers.
Maximum Allowable Exhaust Vent Pipe Length (in ft.) Without Insulation
In Unconditioned Space For Winter Design Temperatures
Winter Design Temperatures1
ºF (ºC)
Unit Input Size
Vent Pipe
Diameter
045
PVC
32 to 21
(0 to -6)
070
2
PP
PVC
090
2
PP
PVC
110
PP
PVC
46
42
30
30
2
2
PP
2 in.
21
18
33
30
2-1/2 in.
16
N/A
26
N/A
37
N/A
36
N/A
3 in.
12
12
21
21
30
30
29
29
20 to 1
(-7 to -17)
2 in.
11
9
19
17
28
25
27
24
2-1/2 in.
7
N/A
14
N/A
21
N/A
20
N/A
3 in.
N/A
N/A
9
9
16
16
14
14
0 to -20
(-18 to -29)
2 in.
6
4
12
10
19
16
18
15
2-1/2 in.
N/A
N/A
7
N/A
13
N/A
12
N/A
3 in.
N/A
N/A
N/A
N/A
8
8
7
7
Refer to 99% Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook.
Poly-Propylene vent pipe (PP) by Duravent and Centrotherm
NOTE - Concentric terminations are the equivalent of 5’ and should be considered when measuring pipe length.
1
2
NOTE- Maximum uninsulated vent lengths listed may include the termination (vent pipe exterior to the structure ) and cannot
exceed 5 linear feet or the maximum allowable intake or exhaust vent length listed in table 5 or 6.
NOTE - If insulation is required an unconditioned space, it must be located on the pipe closed to the furnace.
Table 8
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507052-04
Vent Termination Clearances
For Non-Direct Vent Installations in the USA and Canada
Figure 26
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Page 23 of 58
Vent Termination Clearances
For Direct Vent installations in the USA and Canada
Figure 27
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Issue 1621
507052-04
Details of Intake and Exhaust Piping Terminations for
Direct Vent Installations
Direct Vent Roof Termination Kit
NOTE: In Direct Vent installations, combustion air is taken
from outdoors and flue gases are discharged to outdoors.
NOTE: Flue gas may be slightly acidic and may adversely
affect some building materials. If any vent termination
is used and the flue gases may impinge on the building
material, a corrosion-resistant shield (minimum 24 inches
square) must be used to protect the wall surface. If the
optional tee is used, the protective shield is required.
The shield should be constructed using wood, plastic,
sheet metal or other suitable material. All seams, joints,
cracks, etc. in the affected area should be sealed using an
appropriate sealant. See Figure 32.
Intake and exhaust pipes may be routed either horizontally
through an outside wall or vertically through the roof. In attic
or closet installations, vertical termination through the roof is
preferred. Figures 28 through 38 show typical terminations.
1. Vent terminations are not required to be in the same
pressure zone. You may exit the intake on one side of
the structure and the exhaust on another side (Figure
29). You may exit the exhaust out the roof and the intake
out the side of the structure (Figure 30).
2. Intake and exhaust pipes should be placed as close
together as possible at termination end (refer to
illustrations). Maximum separation is 3” (76 mm) on roof
terminations and 6” (152 mm) on side wall terminations.
3. On roof terminations, the intake piping should terminate
straight down using two 90° elbows (See Figure 28).
4. Exhaust piping must terminate straight out or up as
shown. A reducer may be required on the exhaust piping
at the point where it exits the structure to improve the
velocity of exhaust away from the intake piping. See
Table 9.
Figure 28
Figure 29
Exhaust Pipe Termination Size Reduction
Table 9
5. On field supplied terminations for side wall exit, exhaust
piping may extend a maximum of 12 inches (305 mm)
for 2” PVC and 20 inches (508 mm) for 3” (76 mm) PVC
beyond the outside wall. Intake piping should be as
short as possible. See Figures 33 and 34.
NOTE: Care must be taken to avoid recirculation of exhaust
back into intake pipe.
507052-04
Issue 1621
Figure 30
Page 25 of 58
Flush Mount Side Wall Termination
Figure 31
6. On field supplied terminations, a minimum distance
between the end of the exhaust pipe and the end of
the intake pipe without a termination elbow is 8” and a
minimum distance of 6” with a termination elbow. See
Figures 33 and 34.
7. If intake and exhaust piping must be run up a side wall to
position above snow accumulation or other obstructions,
piping must be supported every 24” (610 mm) as shown
in Figures 33 and 34.
When exhaust and intake piping must be run up an
outside wall, the exhaust piping must be terminated
with pipe sized per Table 9. The intake piping may be
equipped with a 90° elbow turndown. Using turndown
will add 5 feet (1.5 m) to the equivalent length of the
pipe.
8. Based on the recommendation of the manufacturer, a
multiple furnace installation may use a group of up to
four terminations assembled together horizontally, as
shown in Figure 37
Page 26 of 58
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507052-04
Figure 32
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Page 27 of 58
Field Supplied Wall Termination
Field Supplied Wall Termination
Figure 33
Figure 34
Page 28 of 58
Issue 1621
507052-04
Direct Vent Concentric Rooftop Termination
Optional Vent Termination for Multiple Unit
Installation of Direct Vent Wall Termination Kit
Figure 37
Figure 35
Direct Vent Application Using Existing Chimney
Direct Vent Concentric Wall Termination
Figure 36
Figure 38
507052-04
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Page 29 of 58
Details of Exhaust Piping Terminations for Non-Direct
Vent Applications
Exhaust pipe may be routed either horizontally through
an outside wall or vertically through the roof. In attic or
closet installations, vertical termination through the roof is
preferred. Figures 39 through 42 show typical terminations.
Non-Direct Vent Field Supplied Wall Termination
Extended
1. Exhaust piping must terminate straight out or up as
shown. The termination pipe must be sized as listed
in Table 9. The specified pipe size ensures proper
velocity required to move the exhaust gases away from
the building.
2. On field supplied terminations for side wall exit, exhaust
piping may extend a maximum of 12 inches (305 mm) for
2” PVC and 20” (508 mm) for 3” (76 mm) PVC beyond
the outside wall. See Figure 40.
3. If exhaust piping must be run up a sidewall to position
above snow accumulation or other obstructions, piping
must be supported every 24” (610 mm) as shown in
Figure 41. When exhaust piping must be run up an
outside wall, any reduction in exhaust pipe size must
be done after the final elbow.
Figure 41
Non-Direct Vent Roof Termination Kit
Non-Direct Vent Application Using Existing Chimney
Figure 39
Non-Direct Vent Field Supplied Wall Termination
Figure 42
Figure 40
Page 30 of 58
Issue 1621
507052-04
Condensate Piping
This unit is designed for either right or left side exit of
condensate piping in downflow applications.
Refer to
Figure 43 for condensate trap locations.
Condensate Trap and Plug Locations
NOTE: If necessary the condensate trap may be installed
up to 5 feet away using PVC pipe from the furnace. Piping
from furnace must slope down a minimum of 1/4” per ft.
toward trap.
1. Determine which side condensate piping will exit the
unit, location of trap, field-provided fittings and length
of PVC pipe required to reach available drain.
2. Use a large flat head screw driver or a 1/2” drive socket
extension and remove plug (Figure 43) from the cold
end header box at the appropriate location on the side
of the unit. Install provided 3/4 NPT street elbow fitting
into cold end header box. Use Teflon tape or appropriate
pipe dope.
3. Install the cap over the clean out opening at the base
of the trap. Secure with clamp. See Figure 48.
4. Install drain trap using appropriate PVC fittings, glue
all joints. Glue the provided drain trap as shown in
Figure 48. Route the condensate line to an open drain.
Condensate line must maintain a 1/4” downward slope
from the furnace to the drain.
Figure 43
CAUTION
Do Not use copper tubing or existing copper condensate
lines for drain line.
507052-04
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Page 31 of 58
NOTE: Vinyl tubing may be used for condensate drain.
Tubing must be 1-1/4” ODX1”ID and should be attached
to the drain on the trap using a hose clamp.
5. Figure 45 shows the furnace and evaporator coil using
a separate drain. If necessary, the condensate line from
the furnace and evaporator coil can drain together. See
Figure 46. The field provided vent must be a minimum
1” to a maximum 2” length above the condensated drain
outlet connection.
Condensate line must slope downward away from the trap
to drain. If drain level is above condensate trap, condensate
pump must be used. Condensate drain line should be routed
within the conditioned space to avoid freezing of condensate
and blockage of drain line. If this is not possible, a heat
cable kit may be used on the condensate trap and line.
Heating cable kit is available in various lengths; 6 ft. (1.8
m) - kit no. 26K68; 24 ft. (7.3 m) - kit no. 26K69; and 50 ft.
(15.2 m) - kit no. 26K70.
Evaporator Coil Using a Separate Drain
Condensate Trap Location
(shown with right side exit of condensation)
Figure 45
Figure 44
6. If unit will be started immediately upon completion of
installation, prime trap per procedure outlined in Unit
Start-Up section.
Page 32 of 58
Issue 1621
CAUTION
Do Not use copper tubing or existing copper condensate
lines for drain line.
507052-04
CAUTION
When combining the furnace and evaporator coil
drains together, the A/C condensate drain outlet
must be vented to relieve pressure in order for the
furnace pressure switch to operate properly.
Ecaporator Coil Using a Common Drain
Figure 46
Condensate Trap with Optional Overflow Switch
Figure 47
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Page 33 of 58
TRAP DRAIN ASSEMBLY USING 1/2” PVC or 3/4” PVC
Figure 48
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507052-04
Gas Piping
IMPORTANT
Compounds used on threaded joints of gas piping must
be resistant to the actions of liquified petroleum gases.
CAUTION
If a flexible gas connector is required or allowed by the
authority that thas jurisdiction, black iron pipe shall be
installed at the gas valve and extend outside the furnace
cabinet. The flexible connector can then be added
between the black iron pipe and the gas supply line.
Leak Check
After gas piping is completed, carefully check all piping
connections (factory and field installed) for gas leaks. Use
a leak detecting solution or other preferred means.
The furnace must be isolated from the gas supply system
by closing its individual manual shut off valve during any
pressure testing of the gas supply system at pressures
greater than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).
WARNING
Do Not exceed 600 in. lbs. (50 ft. lbs.) torque when
attaching the gas piping to the gas valve.
1. Gas piping may be routed into the unit through either
the left or right hand side. Supply piping enters into the
gas valve from the side of the valve as shown in Figure
50. Move bellows grommet to side of the cabinet which
the gas line enters. Ensure opposite gas line entrance
is plugged with supplied plug.
IMPORTANT
Figure 49
A low inlet pressure switch in LP/propane applications
is recommended.
2. When connecting gas supply, factors such as length
of run, number of fittings and furnace rating must be
considered to avoid excessive pressure drop. Table 10
lists recommended pipe sizes for typical applications.
NOTE: Use two wrenches when connecting gas piping to
avoid transferring torque to the manifold.
3. Gas piping must not run in or through air ducts, clothes
chutes, chimneys or gas vents, dumb waiters or elevator
shafts. Center gas line through piping hole. Gas line
should not touch side of unit. See Figures 50.
4. Piping should be sloped 1/4 inch per 15 feet (6 mm per
5.6 m) upward toward the gas meter from the furnace.
The piping must be supported at proper intervals, every
8 to 10 feet (2.44 to 3.05 m), using suitable hangers or
straps. Install a drip leg in vertical pipe runs to serve
as a trap for sediment or condensate.
5. A 1/8” N.P.T. plugged tap or pressure post is located on
the gas valve to facilitate test gauge connection.
6. In some localities, codes may require installation of a
manual main shut off valve and union (furnished by
installer) external to the unit. Union must be of the
ground joint type.
507052-04
Issue 1621
IMPORTANT
When testing pressure of gas lines, gas valve must
be disconnected and isolated. Gas Valves can be
damaged if subjected to pressures greater than 1/2
psig (3.48 kPa).
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could
result in serious injury, death, or property damage.
Never use an open flame to test for gas leaks. Check
all connections using a commercially available soap
solution made specifically for leak detection. Some
soaps used for leak detection are corrosive to certain
metals. Carefully rinse piping thoroughly after leak test
has been completed.
Page 35 of 58
Figure 50
Table 10
Page 36 of 58
Issue 1621
507052-04
Electrical
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and service
to protect the furnace’s electronic controls. Precautions
will help to avoid control exposure to electrostatic
discharge by putting the furnace, the control and the
technician at the same electrostatic potential. Neutralize
electrostatic charge by touching hand and all tools on
an unpainted unit surface, such as the gas valve or
blower deck, before performing any service procedure.
INTERIOR MAKE-UP BOX INSTALLATION
The unit is equipped with a field makeup box. The makeup
box may be installed on the exterior of the right side of the
furnace to facilitate installation. Seal unused openings
on left side with plugs removed from right side. Secure
the excess wire to the existing harness to protect it from
damage.
Refer to Figure 55 for field wiring and Figure 56 for schematic
wiring diagram and troubleshooting.
1. The power supply wiring must meet Class I restrictions.
Protected by either a fuse or circuit breaker, select circuit
protection and wire size according to unit nameplate.
NOTE: Unit nameplate states maximum current draw.
Maximum over current protection allowed is shown in Table
11.
2. Holes are on both sides of the furnace cabinet to
facilitate wiring.
3. Install a separate (properly sized) disconnect switch
near the furnace so that power can be turned off for
servicing.
Table 11
Figure 51
INTERIOR MAKE-UP BOX INSTALLATION
4. Before connecting the thermostat, check to make sure
the wires will be long enough for servicing at a later
date. Make sure that thermostat wire is long enough
to facilitate future removal of blower for service.
5. Complete the wiring connections to the equipment. Use
the provided unit wiring diagram and the field wiring
diagram shown in Figure 55. Use 18 gauge wire or
larger that is suitable for Class II rating for thermostat
connections.
6. Electrically ground the unit according to local codes or,
in the absence of local codes, according to the current
National Electric Code (ANSI/NFPA No. 70). A green
ground wire is provided in the field make-up box.
NOTE: This furnace contains electronic components that
are polarity sensitive. Make sure that the furnace is wired
correctly and is properly grounded.
Figure 52
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Page 37 of 58
7. One line voltage “EAC” 1/4” spade terminal is provided
on the furnace integrated control. Any electronic air
cleaner or other accessory rated up to one amp can
be connected to this terminal with the neutral leg of the
circuit being connected to one of the provided neutral
terminals. This terminal is energized when the indoor
blower is operating.
8. One line voltage “HUM” 1/4” spade terminal is provided
on the furnace integrated control. Any humidifier rated
up to one amp can be connected to this terminal with the
neutral leg of the circuit being connected to one of the
provided neutral terminals. This terminal is energized in
the heating mode whenever the combustion air inducer
is operating.
9. Install the room thermostat according to the instructions
provided with the thermostat. If the furnace is being
matched with a heat pump, refer to the instruction
packaged with the dual fuel thermostat.
Electrical Wiring
WARNING
Risk of electrical shock. Disconnect electrical power
at the circuit breaker or service panel before making
electrical connections. Failure to disconnect power
supplies can result in property damage, personal injury,
or death.
The furnace must be grounded and wired in accordance
with local codes or, in the absence of local codes, with the
National Electrical Code ANSI/NFPA No. 70 (latest edition)
and/or CSA C22.1 Electrical Code (latest edition) if an
external electrical source is utilized.
In all instances, other than wiring for the thermostat, the
wiring to be done and any replacement of wire shall conform
with the temperature limitation for Type T wire –63°F (35°C)
rise.
Indoor Blower Speeds
1. When the thermostat is set to “FAN ON,” the indoor
blower will run continuously at approximately 50% of the
second stage cooling speed when there is no cooling
or heating demand.
Connect a sufficiently sized wire with ground to the furnace’s
line voltage connections and ground wire. Refer to the
furnace rating plate for electrical characteristics to be used
in sizing field supply wiring and overcurrent protection.
2. When this unit is running in the heating mode, the indoor
blower will run on the heating speed designated by
the positions of DIP switches 1 (A,B,C,D) of the HEAT
jumper plug. See Figure 54.
The line voltage supply should be routed through a readily
accessible disconnect located within sight of the furnace.
A junction box on the furnace side panel is provided for line
voltage connections. Refer to the furnace wiring diagram
for specific connection information.
3. When there is a cooling demand, the indoor blower will
run on the cooling speed designated by the positions
of DIP switches (A, B, C, D) of the COOL jumper plug.
See Figure 54.
Proper polarity of the supply connections (“HOT” and
“NEUTRAL”) must be observed to ensure that safety
controls provide the protection intended.
Generator Use - Voltage Requirements
The following requirements must be kept in mind when
specifying a generator for use with this equipment:
The furnace requires 120 volts ± 10% (Range: 108 volts
to 132 volts).
• The furnace operates at 60 Hz ± 5% (Range: 57 Hz to
63 Hz).
• The furnace integrated control requires both polarity
and proper ground. Both polarity and proper grounding
should be checked before attempting to operate the
furnace on either permanent or temporary power.
• Generator should have a wave form distortion of less
than 5% THD (Total Harmonic Distortion).
•
Page 38 of 58
A connection to the unit’s ground wire and actual earth
ground (typically a ground stake or buried steel pipe) must
be maintained for proper operation.
Thermostat
Install a room thermostat according to the instructions
furnished with it. Select a location on an inside wall that is
not subject to drafts, direct sunshine, or other heat sources.
The initial heat anticipator setting should be equal to the total
current draw of the control circuit. Low voltage thermostat
connections are to be made to the integrated ignition/blower
control board as indicated on the wiring diagram.
Issue 1621
507052-04
Single Stage Thermostat Operation
(A95DF2V and 95G2DFV Models )
The automatic heat staging option allows a single stage
thermostat to be used with two stage furnace models
(A95DF2V or 95G2DFV). To activate this option, move the
jumper pin (see Figure 53) to desired setting (5 minutes or
10 minutes). The furnace will start on 1st stage heat and
stay at 1st stage heat for the duration of the selected time
before switching to 2nd stage heat.
W1 on the control board must be connected to W1 on the
thermostat.
AUTOMATIC HEAT STAGING JUMPER
Figure 53
Humidifier
Terminals are provided on the integrated ignition/blower
control board for connection to a 120-volt humidifier. The
“HUM” terminal is energized whenever the thermostat
calls for heat. See the furnace wiring diagram for specific
connection information.
Electronic Air Cleaner
Terminals are provided on the integrated ignition/blower
control board for connection of a 120-volt electronic air
cleaner. The “EAC” terminal is energized whenever the
thermostat calls for heat, cooling, or continuous blower. See
furnace wiring diagram for specific connection information.
Variable Speed Features
This furnace is equipped with a variable speed circulation
air blower motor that will deliver a constant airflow within a
wide range of external static pressures. Other features of
this variable speed motor include:
Soft Start
The variable speed motor will slowly ramp up to normal
operating speed. This minimizes noise and increases
comfort by eliminating the initial blasts of air encountered
with standard motors.
507052-04
Soft Stop
At the end of a cooling or heating cycle, the variable speed
motor will slowly ramp down after a short blower “off” delay.
If continuous blower operation has been selected, the
variable speed motor will slowly ramp down until it reaches
the airflow for that mode.
Passive and Active Dehumidification
Passive Dehumidification
For situations where humidity control is a problem, a
dehumidification feature has been built into the variable
speed motor. At the start of each cooling cycle, the variable
speed motor will run at 82% of the rated airflow for 7.5
minutes. After 7.5 minutes has elapsed, the motor will
increase to 100% of the rated airflow.
Active Dehumidification
To achieve additional dehumidification, clip the jumper
wire located below the DEHUM terminal on the integrated
ignition/blower control board and connect a humidity
control that opens on humidity rise to the DEHUM and R
terminals. The DEHUM terminal on the control board must
be connected to the normally closed contact of the humidity
control so that the board senses an open circuit on high
humidity. In this setup, the variable speed motor will operate
at a 30% reduction in the normal cooling airflow rate when
there is a call for dehumidification.
Both the passive and active dehumidification methods
described above can be utilized on the same furnace.
Circulating Airflow Adjustments
Cooling Mode
The units are factory set for the highest airflow for each
model. Adjustments can be made to the cooling airflow by
repositioning the jumper plug marked COOL – A, B, C, D (see
Figure 52). To determine what CFM the motor is delivering
at any time, count the number of times the amber LED on
the control board flashes. Each flash signifies 100 CFM;
count the flashes and multiply by 100 to determine the actual
CFM delivered (for example: 10 flashes x 100 = 1000 CFM).
Heating Mode
These units are factory set to run at the middle of the heating
rise range as shown on the unit rating plate. If higher or
lower rise is desired, reposition the jumper plug marked
HEAT - A, B, C, C (see Figure 50) . To determine what
CFM the motor is delivering at any time, count the number
of times the amber LED on the control board flashes. Each
flash signifies 100 CFM; count the flashes and multiply by
100 to determine the actual CFM delivered (for example:
10 flashes x 100= 1000.
Issue 1621
Page 39 of 58
Adjust Tap
Airflow amounts may be increased or decreased by 10% by
moving the ADJUST jumper plug (see Figure 54) from the
NORM position to the (+) or (-) position. Changes to the
ADJUST tap will affect both cooling and heating airflows.
The TEST position on the ADJUST tap is not used.
Continuous Blower Operation
The comfort level of the living space can be enhanced when
using this feature by allowing continuous circulation of air
between calls for cooling or heating. The circulation of air
occurs at half the full cooling airflow rate.
To engage the continuous blower operation, place the
fan switch on the thermostat into the ON position. A call
for fan from the thermostat closes R to G on the ignition
control board. The control waits for a 1 second thermostat
debounce delay before responding to the call for fan by
ramping the circulating blower up to 50% of the cooling
speed. When the call for continuous fan is satisfied, the
control immediately ramps down the circulating blower.
ADJUST, HEAT, and COOL Taps
on Integrated Ignition/Blower
Control Board
Sequence of Operation
Heating
On a call for heat from the room thermostat, the control board
performs a 1 second self check. Upon confirmation that the
pressure switch contacts are in an open position, the control
energizes the combustion blower on high speed. The control
then checks for adequate combustion air by making sure
the low-fire pressure switch contacts are closed.
The igniter energizes and is allowed to warm up for 20
seconds before the gas valve energizes on 1st stage and
burners ignite. 45 seconds after the control confirms ignition
has occurred, the control drops the combustion blower to
low speed.
The circulating blower ramps up to 50% of 1st stage heat
speed and operates at that speed for one minute (including
ramp up time), then at 75% of 1st stage heat speed for an
additional minute. After that, the circulating blower operates
at full 1st stage heat speed until either the heat call is satisfied
or the thermostat initiates a call for 2nd stage heat. On a call
for 2nd stage heat, the control energizes the circulating air
blower on full CFM 2nd stage heat.
If the automatic heat staging option is being used the
furnace does not switch to 2nd stage heat in response to a
call from the thermostat but instead operates at 1st stage heat
for the duration of the selected time before automatically
switching to 2nd stage heat.
When the call for heat is satisfied, the gas valve and
combustion air blower shut down. The control board shuts
off the gas valve and runs the combustion blower for an
additional 15 seconds. The circulating air blower continues
to run for 2 minutes at 82% of the selected heating speed
(low fire or high fire) before ramping down.
Figure 54
In the event the unit loses ignition, the control will attempt to
recycle up to five times before it goes into a 1 hour lockout.
Lockout may be manually reset by removing power from the
control for more than 1 second or removing the thermostat
call for heat for more than 3 seconds.
If during a heating cycle the limit control senses an abnormally
high temperature and opens, the control board de-energizes
the gas valve and the combustion blower while the circulating
blower ramps up to 2nd stage heat speed. The circulating
blower remains energized until the limits are closed.
Fan On
When the thermostat is set for continuous fan operation
and there is no demand for heating or cooling, a call for
fan closes
the R to G circuit and the circulating blower motor runs at 50%
of the selected cooling CFM until switched off. When the call for fan is
turned OFF, the control de-energizes the circulating blower.
Page 40 of 58
Issue 1621
507052-04
Cooling
The unit is set up at the factory for single stage cooling. For
two stage cooling operation, clip the jumper wire located
between the Y to Y2 terminals on the integrated ignition/
blower control board.
If the active dehumidification feature is enabled, the
circulating blower runs at 70% of the selected cooling speed
as long as there is a call for dehumidification.
WARNING
The system must not be in either the passive or active
dehumidification mode when charging a cooling system.
Single Stage Cooling
A call for cooling from the thermostat closes the R to Y circuit
on the integrated ignition/blower control board. The control
waits for a 1-second delay before energizing the circulating
blower to 82% of the selected cooling CFM (passive
dehumidification mode). After 7.5 minutes, the circulating
blower automatically ramps up to 100% of the selected
cooling airflow. When the call for cooling is satisfied, the
circulating blower ramps back down to 82% of the selected
cooling airflow for 1 minute, then shuts off.
Two Stage Cooling
A call for 1st stage cooling from the thermostat closes the
R to Y circuit on the control board. The control waits for
a 1-second delay before energizing the circulating blower.
The blower motor runs at 57% of the selected air flow for the
first 7.5 minutes of the 1st stage cooling demand (passive
dehumidification mode). After 7.5 minutes, the blower motor
runs at 70% of the selected cooling air flow until 1st stage
cooling demand is satisfied.
Heat Pump
For heat pump operation, clip the jumper wire located below
the O terminal on the integrated ignition/blower control board.
In heat pump mode, a call for heat will result in the circulating
air blower operating at the selected cooling airflow after a
brief ramp-up period.
Emergency Replacement Motor Operation
If the variable speed motor needs to be replaced in an
emergency situation (such as “no heat”) and an exact
replacement motor is not immediately available, a standard
PSC motor of equivalent frame size, voltage, rotation, and
horsepower can be temporarily installed until the correct
replacement motor can be obtained.
Connect the desired speed tap to the “EAC” terminal and
the neutral tap to the neutral terminal on the ignition control
(refer to the furnace wiring diagram). The ignition control will
control the motor’s operation, including a nominal 20 second
“on” delay with a call for heat and a nominal 180 second “off”
delay when the thermostat is satisfied. It will also operate
the motor on a call for cooling, with no “on” or “off” delays.
Verify that the unit is operating at the desired speed and
within the rise range as shown on the unit rating plate.
The correct replacement motor must be installed as
soon as possible to ensure continued satisfactory
operation of the furnace.
A call for 2nd stage cooling from the thermostat closes the
R to Y2 circuit on the control board. The blower motor
ramps up to 100% of the selected cooling air flow. When
the demand for cooling is met, the blower ramps down to
Y1 until satisfied, then ramps down to 57% for 1 minute,
then turns off.
507052-04
Issue 1621
Page 41 of 58
Control Diagnostics
FAILURE CODES - Red LED
Troubleshooting
Make the following visual checks before troubleshooting:
1. Check to see that the power to the furnace and the
integrated ignition/blower control board is ON.
2. The manual shutoff valves in the gas line to the furnace
must be open.
3. Make sure all wiring connections are secure.
4. Review the Sequence of Operation.
Start the system by setting thermostat above room
temperature. Observe system response. Then use the
information provided in this section to check the system
operation.
The furnace has a built-in, self-diagnostic capability. If a
system problem occurs, a fault code is shown by a red LED
on the control board. The control continuously monitors its
own operation and the operation of the system. If a failure
occurs, the LED will indicate the failure code. The flash
codes are presented in Table 12.
Fault Code History Button
The control stores the last five fault codes in memory. A
pushbutton switch is located on the control. When the
pushbutton switch is pressed and released, the control
flashes the stored fault codes. The most recent fault code
is flashed first; the oldest fault code is flashed last. To clear
the fault code history, press and hold the pushbutton switch
in for more than 5 seconds before releasing.
High Heat State LED
On A95DF2V and 95G2DFV models, a green LED is
provided on the control board to indicate high heat state
(see Table 13).
CFM LED
On A95DF2V and 95G2DFV models equipped with a
variable speed motor, an amber LED is provided on the
control board to display CFM. To determine what CFM the
motor is delivering at any time, count the number of times
the amber LED flashes. Each flash signifies 100 CFM; count
the flashes and multiply by 100 to determine the actual CFM
delivered (for example: 10 flashes x 100 = 1000 CFM).
Page 42 of 58
Issue 1621
Table 12
HIGH HEAT STATE - Green LED
Table 13
507052-04
TYPICAL FIELD WIRING DIAGRAM
WARNING:
ELECTRIC SHOCK HAZARD, CAN CAUSE INJURY
OR DEATH. UNIT MUST BE GROUNDED IN
ACCORDANCE WITH NATIONAL AND LOCAL
CODES
NOTE:
IF ANY WIRE IN THIS APPLIANCE IS REPLACED,
IT MUST BE REPLACED WITH WIRE OF LIKE
SIZE, RATING, INSULATION THICKNESS AND
TERMINATION
FIELD SUPPLIED ACC. WIRE
S145 IS USED WITH HONEYWELL GAS VALVE WHEN APPLIED IN LP GAS UNITS
Figure 55
507052-04
Issue 1621
Page 43 of 58
TYPICAL WIRING DIAGRAM
NOTES:
1. PRESS AND RELEASE FAULT CODE HISTORY BUTTON TO
DISPAY FAULT CODES. TO ERASE CODES, PRESS AND HOLD
BUTTON IN FOR MORE THAN 5 SECONDS
2.
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL
HAVING A TEMP. RATING OF AT LEAST 90°c.
3.
PROPER POLARITY MUST BE OBERVED FOR FIELD LINE VOLTAGE SUPPLY; IGNITION CONTROL WILL LOCK OUT IF POLARITY IS
REVERSED.
4.
FOR TEMPORARY SERVICE REPLACEMENT OF CIRCULATING BLOWER MOTOR WITH PSC MOTOR, CONNECT DESIRED SPEED TAP
TO “EAC” TERMINAL AND NEUTRAL TAP TO NEUTRAL TERMINAL ON IGNITION CONTROL.
5.
DO NOT CONNECT C (COMMON) CONNECTION BETWEEN INDOOR UNIT AND THEREMOSTAT EXCEPT WHEN REQUIRED BY THE
INDOOR THERMOSTAT. rEFER TO THE THERMOSTAT INSTALLATION INSTRUCTIONS.
Figure 56
Page 44 of 58
Issue 1621
507052-04
Testing for Proper Venting and Sufficient Combustion Air for Non-Direct Vent Applications
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placed into operation could result in carbon monoxide
poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation.
After the gas furnace has been started, the following test
should be conducted to ensure proper venting and sufficient
combustion air has been provided to the unit as well as to
other gas fired appliances which are separately vented.
If this furnace replaces a Category I furnace which was
commonly vented with another gas appliance, the size of the
existing vent pipe for that gas appliance must be checked.
Without the heat of the original furnace flue products, the
existing vent pipe is probably oversized for the single water
heater or other appliance. The vent should be checked for
proper draw with the remaining appliance.
6. Follow the lighting instruction to place the appliance
being inspected into operation. Adjust thermostat so
appliance will operate continuously.
7. Use the flame of a match or candle to test for spillage
of flue gases at the draft hood relief opening after 5
minutes of main burner operation.
8. If improper venting is observed during any of the
above tests, the venting system must be corrected or
sufficient combustion/makeup air must be provided.
The venting system should be resized to approach the
minimum size as determined by using the appropriate
tables in appendix G in the current standards of the
National Fuel Gas Code ANSI-Z223.1/NPFA 54 in the
U.S.A., and the appropriate Natural Gas and Propane
appliances venting sizing tables in the current standard
of the CSA-B149 Natural Gas and Propane Installation
Codes in Canada.
9. After determining that each appliance remaining
connected to the common venting system properly
vents when tested as indicated in step 3, return doors,
windows, exhaust fans, fireplace dampers and any other
gas burning appliance to their previous condition of use.
The test should be conducted while all appliances (both in
operation and those not in operation) are connected to the
venting system being tested. If the venting system has been
installed improperly, or if provisions have not been made
for sufficient amounts of combustion air, corrections must
be made as outlined in the previous section.
1. Seal any unused openings in the venting system.
2. Visually inspect the venting system for proper size
and horizontal pitch. Determine there is no blockage
or restriction, leakage, corrosion, or other deficiencies
which could cause an unsafe condition.
3. To the extent that it is practical, close all building doors
and windows and all doors between the space in which
the appliances connected to the venting system are
located and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliances not
connected to the venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they will operate at maximum speed. Do not operate
a summer exhaust fan.
507052-04
Issue 1621
Page 45 of 58
Priming Condensate Trap
The condensate trap should be primed with water prior to
start-up to ensure proper condensate drainage. Either pour
10 fl. oz. (300 ml) of water into the trap, or follow these steps
to prime the trap:
1. Follow the lighting instructions to place the unit into
operation.
2. Set the thermostat to initiate a heating demand.
3. Allow the burners to fire for approximately 3 minutes.
4. Adjust the thermostat to deactivate the heating demand.
5. Wait for the combustion air inducer to stop. Set the
thermostat to initiate a heating demand and again allow
the burners to fire for approximately 3 minutes.
6. Adjust the thermostat to deactivate the heating demand
and wait for the combustion air inducer to stop. At this
point, the trap should be primed with sufficient water
to ensure proper condensate drain operation.
Unit Start-Up
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
Do not use this furnace if any part has been underwater.
A flood-damaged furnace is extremely dangerous.
Attempts to use the furnace can result in fire or
explosion. Immediately call a qualified service
technician to inspect the furnace and to replace all gas
controls, control system parts, and electrical parts that
have been wet or to replace the furnace, if deemed
necessary.
WARNING
WARNING
Danger of explosion. Can cause
injury or product or property damage.
Should the gas supply fail to shut off or
if overheating occurs, shut off the gas
valve to the furnace before shutting off
the electrical power.
If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or death.
CAUTION
Before attempting to perform any service or maintenance,
turn the electrical power to unit OFF at disconnect
switch.
BEFORE LIGHTING the unit, smell all around the furnace
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
The gas valve on the unit is equipped with a gas control
switch (lever). Use only your hand to move switch. Never
use tools. If the switch will not move by hand, do not try
to repair it. Force or attempted repair may result in a fire
or explosion.
Gas Valve Operation
1. STOP! Read the safety information at the beginning of
this section.
2. Set the thermostat to the lowest setting.
3.Turn OFF all electrical power to the unit.
4. This furnace is equipped with an ignition device which
automatically lights the burners. Do not try to light the
burners by hand.
5. Remove the heating compartment access panel.
6. Move gas valve switch to OFF. See Figure 57.
7. Wait five minutes to clear out any gas. If you then
smell gas, STOP! Immediately call your gas supplier
from a neighbor’s phone. Follow the gas supplier’s
instructions. If you do not smell gas go to next step.
8. Move gas valve switch to ON. See Figure 57.
Placing the furnace into operation:
This furnace is equipped with an automatic hot surface
ignition system. Do not attempt to manually light burners
on this furnace. Each time the thermostat calls for heat, the
burners will automatically light. The ignitor does not get hot
when there is no call for heat on these units.
Page 46 of 58
Issue 1621
507052-04
Gas Pressure Adjustment
Gas Valve Shown In “ON’ Position
Gas Flow (Approximate)
Table 14
Figure 57
9. Replace the heating compartment access panel.
10. Turn on all electrical power to the unit.
11. Set the thermostat to desired setting.
NOTE: When unit is initially started, steps 1 through 11 may
need to be repeated to purge air from gas line.
12. If the appliance will not operate, follow the instructions
“Turning Off Gas to Unit” and call your service technician
or gas supplier.
Turning Off Gas to Unit
1. Set the thermostat to the lowest setting.
2. Turn off all electrical power to the unit if service is to be
performed.
3. Remove the heating compartment access panel.
4. Move gas valve switch to OFF.
5. Replace the heating compartment access panel.
Furnace should operate at least 5 minutes before checking
gas flow. Determine time in seconds for two revolutions of
gas through the meter. (Two revolutions assures a more
accurate time.) Divide by two and compare to time in
Table 14. If manifold pressure matches Table 15 and rate
is incorrect, check gas orifices for proper size and restriction.
Remove temporary gas meter if installed.
NOTE: To obtain accurate reading, shut off all other gas
appliances connected to meter.
Supply Pressure Measurement
A pressure post on the inlet side of the gas valve
provides access to the supply pressure. Back out the
3/32 Hex screw one turn, connect a piece of 5/16”
tubing and connect a manometer to measure supply
pressure.
NOTE: Shut unit off and remove manometer as soon as an
accurate reading has been obtained. Take care to re-tighten
the 3/32 Hex screw.
Manifold Pressure Measurement
1. A manifold post located on the gas valve provides
access to the manifold pressure. See Figure 57. Back
out the 3/32 Hex screw one turn, connect a piece of
5/16” tubing and connect to a manometer to measure
manifold pressure.
2. Start unit and allow 5 minutes for unit to reach steady
state.
3. While waiting for the unit to stabilize, observe the flame.
Flame should be stable and should not lift from burner.
Natural gas should burn blue.
4. After allowing unit to stabilize for 5 minutes, record
manifold pressure and compare to value given in Table
15.
NOTE: Shut unit off and remove manometer as soon as an
accurate reading has been obtained. Take care to re-tighten
the 3/32 Hex screw.
507052-04
Issue 1621
Page 47 of 58
Manifold and Supply Line Pressures Altitudes
Manifold Pressure in w.g.
A95DF2E
95G2DFE
All Models
Gas
0 - 4500 ft.
4501 - 5500 ft.
5501 - 6500ft.
6501 - 7500ft.
Low
Fire
Low
Fire
Low
Fire
Low
Fire
High
Fire
High
Fire
High
Fire
7501-10000ft.
High
Fire
Low
Fire
High
Fire
Supply Line
Pressure in
w.g.
0 - 10000 ft.
Min.
Max.
Natural
1.7
3.5
1.6
3.3
1.5
3.2
1.5
3.1
1.7
3.5
4.5
13.0
Lp/Propane
4.9
10.0
4.6
9.4
4.4
9.1
4.3
8.9
4.9
10.0
11.0
13.0
Table 15
Proper Combustion
Furnace should operate minimum 15 minutes with correct
manifold pressure and gas flow rate before checking
combustion. Take combustion sample beyond the flue outlet
and compare to the tables below. The maximum carbon
monoxide reading should not exceed 100 ppm.
CO2% for Nat
CO2% for L.P.
A96DF2V
95G2DFV
Low Fire
High Fire
Low Fire
High Fire
045
5.6 - 6.6
7.8 - 8.8
6.6 - 7.6
9.1 - 10.1
070
5.5 - 6.5
7.3 - 8.3
6.5 - 7.5
8.6 - 9.6
090
5.9 - 6.9
7.8 - 8.8
6.9 - 7.9
9.1 - 10.1
110
6.3 - 7.3
8.2 - 9.2
7.3 - 8.3
9.5 - 10.5
High Altitude Information
NOTE: In Canada, certification for installations at elevations
over 4500 feet (1371 m) is the jurisdiction of local authorities.
Units may be installed at altitudes up to 10,000 ft. above
sea level without manifold adjustment. Units installed
at altitude of 4501 - 10,000 feet (1371 to 3048 m) may
require a pressure switch change which can be ordered
separately. Table 17 lists conversion kit and pressure switch
requirements at varying altitudes.
The combustion air pressure switch is factory-set and
requires no adjustment.
The maximum carbon monoxide reading should not exceed 100 ppm.
NOTE: A natural to LP/propane gas changeover kit is
necessary to convert this unit. Refer to the changeover kit
installation instruction for the conversion procedure.
Table 16
Conversion Kit Fan Pressure Switch Requirements at Varying Altitudes
A95DF2E
95G2DFE
Natural to LP/
Propane
High Altitude
Natural Burner
Orifice Kit
High Altitude
LP/Propane Burner
Orifice Kit
0 - 7500 ft
(0 - 2286m)
7501 - 10000 ft
(2286 - 3048m)
7501 - 10000 ft
(2286 - 3048m)
High Altitude Pressure switch
4501 - 7500 ft
(1371 - 2286m)
7501 - 10000 ft
(2286 - 3048m)
045
14A47
14A50
070
14A55
14A56
14A54
14A53
14A46
14A51
090
11K48
*51W01
11K47
110
*Conversion requires installation of a gas valve manifold spring which is provided with the gas conversion kit.
Pressure switch is factory set. No adjustment necessary. All models use the factory-installed pressure switch from 0-4500 feet (0-1371 m).
Table 17
Page 48 of 58
Issue 1621
507052-04
Other Unit Adjustments
Primary Limit
The primary limit is located on the heating compartment
vestibule panel. This limit is factory set and requires no
adjustment.
Flame Rollout Switches (Two)
These manually reset switches are located on the front of
the burner box. These limits are factory set and require no
adjustment.
Pressure Switch
The pressure switch is located in the heating compartment
on the cold end header box. This switch checks for proper
combustion air inducer operation before allowing ignition
trial. The switch is factory set and must not be adjusted.
Temperature Rise
After the furnace has been started and supply and return
air temperatures have been allowed to stabilize, check the
temperature rise. If necessary, adjust the blower speed to
maintain the temperature rise within the range shown on the
unit nameplate. Increase the blower speed to decrease the
the temperature. Decrease the blower speed to increase
the temperature rise. Failure to adjust the temperature rise
may cause erratic limit operation.
Fan Control
The fan ON time of 30 seconds is not adjustable. The fan
OFF delay (amount of time that the blower operates after
the heat demand has been satisfied) is 120 seconds and
is not adjustible.
507052-04
Thermostat Heat Anticipation
Set the heat anticipator setting (if adjustable) according to
the amp draw listed on the wiring diagram that is attached
to the unit.
Electrical
1. Check all wiring for loose connections.
2. Check for the correct voltage at the furnace (with furnace
operating). Correct voltage is 120 VAC ± 10%.
3. Check amp–draw on the blower motor with the blower
compartment access panel in place.
Motor Nameplate__________Actual__________
Electronic Ignition
The integrated control has an added feature of an internal
Watchguard control. The feature serves as an automatic
reset device for integrated control lockout caused by ignition
failure. This type of lockout is usually due to low gas line
pressure. After one hour of continuous thermostat demand
for heat, the Watchguard will break and remake thermostat
demand to the furnace and automatically reset the integrated
control to begin the ignition sequence.
Exhaust and Air Intake Pipe
1. Check exhaust and air intake connections for tightness
and to make sure there is no blockage.
2. Is pressure switch closed? Obstructed exhaust pipe
will cause unit to shut off at pressure switch. Check
termination for blockages.
3. Obstructed pipe or termination may cause rollout
switches to open. Reset manual flame rollout switches
on burner box assembly if necessary.
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BLOWER DATA A95DF2V & 95G2DFV
Table 18
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BLOWER DATA A95DF2V & 95G2DFV
Table 19
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Service
Electrical
1. Check all wiring for loose connections.
2. Check for the correct voltage at the furnace (furnace
operating). Correct voltage is 120 VAC ± 10%.
3. Check amp-draw on the blower motor with the blower
compartment access panel in place.
Motor Nameplate__________Actual__________
WARNING
ELECTRICAL SHOCK, FIRE,
OR EXPLOSION HAZARD.
Failure to follow safety warnings exactly could result in
dangerous operation, serious injury, death or property
damage.
Winterizing and Condensate Trap Care
1. Turn off power to the furnace.
2. Have a shallow pan ready to empty condensate water.
3. Remove the clean out cap from the condensate trap and
empty water. Inspect the trap then reinstall the clean
out cap.
Improper servicing could result in dangerous operation,
serious injury, death, or property damage.
Before servicing, disconnect all electrical power to
furnace.
When servicing controls, label all wires prior to
disconnecting. Take care to reconnect wires correctly.
Verify proper operation after servicing.
At the beginning of each heating season, system should be
checked as follows by a qualified service technician:
Blower
Check the blower wheel for debris and clean if necessary.
The blower motors are prelubricated for extended bearing
life. No further lubrication is needed.
WARNING
The blower access panel must be securely in place
when the blower and burners are operating. Gas fumes,
which could contain carbon monoxide, can be drawn
into living space resulting in personal injury or death.
NOTE: If necessary, clean burners at this time. Follow
procedures outlined in Burner Cleaning section.
Filters
All air filters are installed external to the unit. Filters should
be inspected monthly. Clean or replace the filters when
necessary to ensure proper furnace operation. Table 3 lists
recommended filter sizes.
Exhaust and air intake pipes
Check the exhaust and air intake pipes and all connections
for tightness and to make sure there is no blockage.
NOTE: After any heavy snow, ice or frozen fog event the
furnace vent pipes may become restricted. Always check
the vent system and remove any snow or ice that may be
obstructing the plastic intake or exhaust pipes.
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Cleaning Heat Exchanger
If cleaning the heat exchanger becomes necessary,
follow the below procedures and refer to Figure 1 when
disassembling unit. Use papers or protective covering in
front of furnace while removing heat exchanger assembly.
1. Turn off electrical and gas supplies to the furnace.
2. Remove the furnace access panels.
3. Disconnect the wires from the gas valve.
4. Remove gas supply line connected to gas valve.
Remove gas valve/manifold assembly.
5. Remove sensor wire from sensor. Disconnect 2 pin
plug from the ignitor.
6. Disconnect wires from flame rollout switches.
7. Loosen clamps at vent elbow. Disconnect condensate
drain tubing from flue collar and remove the vent elbow.
8. Remove four burner box screws at the vestibule panel
and remove burner box. Set burner box assembly aside.
9. Mark and disconnect all combustion air pressure tubing
from cold end header collector box.
10.Mark and remove wires from pressure switches.
Remove pressure switches. Keep tubing attached to
pressure switches.
11.Disconnect the plug from the combustion air inducer.
Remove two screws which secure combustion air
inducer to collector box. Remove combustion air
inducer assembly. Remove ground wire from vest
panel.
12.Remove electrical junction box from the side of the
furnace.
13.Mark and disconnect any remaining wiring to heating
compartment components. Disengage strain relief
bushing and pull wiring and bushing through the hole
in the blower deck.
14.Remove the primary limit from the vestibule panel.
15.Remove two screws from the front cabinet flange at
the blower deck. Spread cabinet sides slightly to allow
clearance for removal of heat exchanger.
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16. Remove screws along vestibule sides and bottom which
secure vestibule panel and heat exchanger assembly
to cabinet. Remove two screws from blower rail which
secure bottom heat exchanger flange. Remove heat
exchanger from furnace cabinet.
17.Back wash heat exchanger with soapy water solution or
steam. If steam is used it must be below 275°F (135°C).
18.Thoroughly rinse and drain the heat exchanger. Soap
solutions can be corrosive. Take care to rinse entire
assembly.
19. Reinstall heat exchanger into cabinet making sure that
the clamshells of the heat exchanger assembly are
resting on the support located at the rear of the cabinet.
Remove the indoor blower to view this area through the
blower opening.
20.Resecure the supporting screws along the vestibule
sides and bottom to the cabinet. Reinstall blower and
mounting screws.
21. Reinstall cabinet screws on front flange at blower deck.
22. Reinstall the primary limit on the vestibule panel.
23. Route heating component wiring through hole in blower
deck and reinsert strain relief bushing.
24. Reinstall electrical junction box.
25. Reinstall the combustion air inducer. Reconnect the
combustion air inducer to the wire harness.
26. Reinstall pressure switches and reconnect pressure
switch wiring.
27. Carefully connect combustion air pressure switch hosing
from pressure switches to proper stubs on cold end
header collector box.
28. Reinstall condensate trap.
29. Reconnect exhaust piping and exhaust drain tubing.
30. Reinstall burner box assembly in vestibule area.
31. Reconnect flame rollout switch wires.
32. Reconnect sensor wire and reconnect 2 pin plug from
ignitor.
33. Secure burner box assembly to vestibule panel using
four existing screws. Make sure burners line up in
center of burner ports.
34. Reinstall gas valve manifold assembly. Reconnect gas
supply line to gas valve.
35. Reconnect wires to gas valve.
36. Replace the blower compartment access panel.
37.Refer to instruction on verifying gas and electrical
connections when re-establishing supplies.
38. Follow lighting instructions to light and operate furnace
for 5 minutes to ensure that heat exchanger is clean
and dry and that furnace is operating properly.
39. Replace heating compartment access panel.
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Cleaning the Burner Assembly
1. Turn off electrical and gas power supplies to furnace.
Remove upper and lower furnace access panels.
2. Disconnect from the gas valve.
3. Remove the burner box cover.
4. Disconnect the gas supply line from the gas valve.
Remove gas valve/manifold assembly.
5. Mark and disconnect sensor wire from the sensor.
Disconnect 2 pin plug from the ignitor at the burner box.
6. Remove four screws which secure burner box assembly
to vest panel. Remove burner box from the unit.
7. Use the soft brush attachment on a vacuum cleaner to
gently clean the face of the burners. Visually inspect the
inside of the burners and crossovers for any blockage
caused by foreign matter. Remove any blockage.
8. Reconnect the sensor wire and reconnect the 2 pin plug
to the ignitor wiring harness.
9. Reinstall the burner box assembly using the existing
four screws. Make sure that the burners line up in the
center of the burner ports.
10. Reinstall the gas valve manifold assembly. Reconnect
the gas supply line to the gas valve. Reinstall the burner
box cover.
11. Reconnect wires to gas valve.
12.Replace the blower compartment access panel.
13.Refer to instruction on verifying gas and electrical
connections when re-establishing supplies.
14. Follow lighting instructions to light and operate furnace
for 5 minutes to ensure that heat exchanger is clean
and dry and that furnace is operating properly.
15.Replace heating compartment access panel.
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Planned Service
A service technician should check the following items during
an annual inspection. Power to the unit must be shut off
for safety.
Fresh air grilles and louvers (on the unit and in the
room where the furnace is installed) - Must be open and
unobstructed to provide combustion air.
Burners - Must be inspected for rust, dirt, or signs of water.
Vent pipe - Must be inspected for signs of water, cracked,
damaged or sagging pipe, or disconnected joints.
Unit appearance - Must be inspected for rust, dirt, signs of
water, burnt or damaged wires, or components.
Blower access door - Must be properly in place and
provide a seal between the return air and the room where
the furnace is installed.
Return air duct - Must be properly attached and provide
an air seal to the unit.
Operating performance - Unit must be observed during
operation to monitor proper performance of the unit and
the vent system.
Combustion gases - Flue products must be analyzed and
compared to the unit specifications.
Problems detected during the inspection may make it
necessary to temporarily shut down the furnace until the
items can be repaired or replaced.
Instruct the homeowners to pay attention to their
furnace. Situations can arise between annual furnace
inspections that may result in unsafe operation. For
instance, items innocently stored next to the furnace may
obstruct the combustion air supply. This could cause
incomplete combustion and the production of carbon
monoxide gas.
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Repair Parts List
The following repair parts are available through Allied Air dealers. When ordering parts, include the complete furnace model
number listed on the CSA nameplate. Example: A95DF2V045B12S-01. All service must be performed by a licensed
professional installer (or equivalent), service agency, or gas supplier.
Cabinet Parts
Heating Compartment Access Panel
Blower Compartment Access Panel
Top Cap
Control Panel Parts
Transformer
Integrated Control Board
Door Interlock Switch
Blower Parts
Blower Wheel
Motor
Motor Mounting Frame
Motor Choke
Blower Housing Cutoff Plate
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Heating Parts
Flame Sensor
Heat Exchanger Assembly
Gas Manifold
Combustion Air Inducer
Gas Valve
Main Burner Cluster
Main Burner Orifices
Pressure Switch
Ignitor
Primary Limit Control
Flame Rollout Switches
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Start-Up & Performance Check List
Page 56 of 58
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UNIT OPERATION
HEATING MODE
1
GAS MANIFOLD PRESSURE “W.C.” ______
2
COMBUSTION SAMPLE CO2 ______%
3
INDOOR BLOWER AMPS ______
4
TEMPERATURE RISE
Supply Duct Temperature ______
_
Return Duct Temperature ______
CO _____ PPM
COOLING MODE
3
INDOOR BLOWER AMPS ______
4
TEMPERATURE DROP
Return Duct Temperature ______
_
Supply Duct Temperature ______
Temperature Drop = ______
5
Temperature Rise = ______
5
TOTAL EXTERNAL STATIC
Supply External Static
Return External Static
Total External Static
6
8
______
DRAIN LINE
Leak Free
______
CONDENSATE LINE
9
THERMOSTAT
Adjusted and Programmed
Leak Free
7
=
Total External Static
______
+ ______
=
TOTAL EXTERNAL STATIC (dry coil)
______
Supply External Static
______
+
Return External Static
Explained Operation to Owner
VENT PIPE
Leak Free
Combustion CO2
2
7
SUPPLY
AIR
Thermostat
Temperatures
8
Gas Manifold Pressure
9
4
1
Blower Motor Amps
6
3
Duct Static
5
RETURN AIR
Contractor’s:
Name______________________________________Telephone________________Checklist Completed____________________
Job Address_______________________________________________________Technician’s Name___________________________________
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REQUIREMENTS for COMMONWEALTH of MASSACHUSETTS
Modifications to NFPA-54, Chapter 10
Revise NFPA-54 section 10.8.3 to add the following
requirements:
For all side wall, horizontally vented, gas-fueled equipment
installed in every dwelling, building or structure used in whole
or in part for residential purposes, including those owned
or operated by the Commonwealth and where the side wall
exhaust vent termination is less than seven (7) feet above
the finished grade in the area of the venting, including but
not limited to decks and porches, the following requirements
shall be satisfied:
1. I N S TA L L AT I O N O F C A R B O N M O N O X I D E
DETECTORS. At the time of installation of the side wall,
horizontally vented, gas-fueled equipment, the installing
plumber or gas fitter shall observe that a hard-wired
carbon monoxide detector with an alarm and battery
backup is installed on the floor level where the gas
equipment is to be installed. In addition, the installing
plumber or gas fitter shall observe that a batteryoperated or hard-wired carbon monoxide detector with
an alarm is installed on each additional level of the
dwelling, building or structure served by the side wall,
horizontally vented, gas-fueled equipment. It shall
be the responsibility of the property owner to secure
the services of qualified licensed professionals for the
installation of hard-wired carbon monoxide detectors.
a. In the event that the side wall, horizontally
vented, g a s - f u e l e d
equipment is installed in a crawl space or an attic, the hard-wired carbon monoxide detector with alarm and battery backup may be installed on the next adjacent floor level.
b. In the event that the requirements of this
subdivision cannot be met
at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery-operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS.
Each carbon monoxide detector as required in
accordance with the above provisions shall comply with
NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall
be permanently mounted to the exterior of the building at
a minimum height of eight (8) feet above grade directly
in line with the exhaust vent terminal for the horizontally
vented, gas-fueled heating appliance or equipment. The
sign shall read, in print size no less than one-half (1/2)
inch in size, “GAS VENT DIRECTLY BELOW. KEEP
CLEAR OF ALL OBSTRUCTIONS.”
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4. INSPECTION. The state or local gas inspector of the
side wall, horizontally vented, gas-fueled equipment
shall not approve the installation unless, upon
inspection, the inspector observes carbon monoxide
detectors and signage installed in accordance with the
provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS: The following equipment is exempt from
24 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment
Not Required to Be Vented” in the most current edition
of NFPA 54 as adopted by the Board; and
2. Product Approved side wall, horizontally vented,
gas-fueled equipment installed in a room or structure
separate from the dwelling, building or structure used
in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side wall,
horizontally vented, gas-fueled equipment provides a
venting system design or venting system components with
the equipment, the instructions provided by the manufacturer
for installation of the equipment and the venting system
shall include:
1. Detailed instructions for the installation of the venting
system design or the venting system components: and
2. A complete parts list for the venting system design or
venting system.
MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of Product Approved sidewall,
horizontally vented, gas-fueled equipment does not provide
the parts for venting the flue gases, but identifies “special
venting systems,” the following requirements shall be
satisfied by the manufacturer:
1. The referenced “special venting system” instructions
shall be included with the appliance or equipment
installation instructions; and
2. The “special venting systems” shall be Product Approved
by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
A copy of all installation instructions for all Product
Approved side wall, horizontally vented, gas-fueled
equipment, all venting instructions, all parts lists
for venting instructions, and/or all venting design
instructions shall remain with the appliance or
equipment at the completion of the installation.
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